Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
  • C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
  • C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
  • C08J9/143—Halogen containing compounds
  • C08J9/144—Halogen containing compounds containing carbon, halogen and hydrogen only
  • C08J9/146—Halogen containing compounds containing carbon, halogen and hydrogen only only fluorine as halogen atoms
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
  • C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
  • C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
  • C08J9/149—Mixtures of blowing agents covered by more than one of the groups C08J9/141 - C08J9/143
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/02—Elements
  • C08K3/04—Carbon
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L25/00—Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
  • C08L25/02—Homopolymers or copolymers of hydrocarbons
  • C08L25/04—Homopolymers or copolymers of styrene
  • C08L25/08—Copolymers of styrene
  • C08L25/12—Copolymers of styrene with unsaturated nitriles
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2201/00—Foams characterised by the foaming process
  • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
  • C08J2201/03—Extrusion of the foamable blend
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2203/00—Foams characterized by the expanding agent
  • C08J2203/14—Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
  • C08J2203/142—Halogenated saturated hydrocarbons, e.g. H3C-CF3
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2203/00—Foams characterized by the expanding agent
  • C08J2203/16—Unsaturated hydrocarbons
  • C08J2203/162—Halogenated unsaturated hydrocarbons, e.g. H2C=CF2
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2203/00—Foams characterized by the expanding agent
  • C08J2203/18—Binary blends of expanding agents
  • C08J2203/182—Binary blends of expanding agents of physical blowing agents, e.g. acetone and butane
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2205/00—Foams characterised by their properties
  • C08J2205/04—Foams characterised by their properties characterised by the foam pores
  • C08J2205/042—Nanopores, i.e. the average diameter being smaller than 0,1 micrometer
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2205/00—Foams characterised by their properties
  • C08J2205/04—Foams characterised by their properties characterised by the foam pores
  • C08J2205/044—Micropores, i.e. average diameter being between 0,1 micrometer and 0,1 millimeter
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2205/00—Foams characterised by their properties
  • C08J2205/04—Foams characterised by their properties characterised by the foam pores
  • C08J2205/052—Closed cells, i.e. more than 50% of the pores are closed
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2325/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
  • C08J2325/02—Homopolymers or copolymers of hydrocarbons
  • C08J2325/04—Homopolymers or copolymers of styrene
  • C08J2325/06—Polystyrene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2325/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
  • C08J2325/02—Homopolymers or copolymers of hydrocarbons
  • C08J2325/04—Homopolymers or copolymers of styrene
  • C08J2325/08—Copolymers of styrene
  • C08J2325/12—Copolymers of styrene with unsaturated nitriles
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2201/00—Properties
  • C08L2201/02—Flame or fire retardant/resistant
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2203/00—Applications
  • C08L2203/14—Applications used for foams

Definitions

• This invention relates to the use of Z-HFO-1336mzz as blowing agent for thermoplastic polymer comprising polystyrene.
• WO 2008/118627 discloses the discovery of blowing agents that have a zero ODP and GWP of less than 50 and solubility in alkenyl polymers, notably polystyrene, that enable these blowing agents comprising more than 50 wt % of the total blowing agent to produce quality foam.
• Table 2 discloses HFO-1336mzz (CF 3 —CH ⁇ CH—CF 3 ) having a moderate solubility as compared to the Table 1 compounds. It is further disclosed that while the alkenes of Table 2 can comprise over 50 wt % of the blowing agent composition, additional blowing agent that is more soluble in the polymer is necessary to achieve quality foam (p. 15, I. 9-12).
• Quality foam is described as the foam having an average cell size of 0.02 to 5 mm, being close-celled, and having a density of 64 kg/m 3 or less. Indicia of lack of quality are small average cell size, density greater than 64 kg/m 3 , high open cell content and blowholes (p. 2, I. 9-13).
• the quality foam is also essentially free of blowholes, which are described as being the size of multiple cell diameters and which can rupture at the foam surface to give an irregular surface (p. 2, I. 15-20).
• the blowholes that do not rupture can be called macrovoids, and the irregular surface caused by the rupturing blowholes is the opposite of a smooth surface (skin).
• the present invention involves the discovery of foaming conditions different from those disclosed for practice of the invention in WO 2008/118627 that enable Z—CF3-CH ⁇ CH—CF3 (Z-HFO-1336mzz, Z-1,1,1,4,4,4-hexafluoro-2-butene) to be useful in foaming thermoplastic polymer comprising polystyrene, with the foamed product of the present invention being free of the indicia of non-quality foam, i.e. having smooth skin and not having macrovoids and/or blowholes.
• One embodiment of the present invention is the process, and the foam produced by said process, comprising extruding a molten composition comprising thermoplastic polymer comprising polystyrene and blowing agent comprising Z-HFO-1,1,1,4,4,4-hexafluoro-2-butene (Z-HFO-1336mzz) under the conditions
• the process, and foam produced by said process comprises extruding a molten composition comprising thermoplastic polymer comprising polystyrene and blowing agent consisting essentially of Z-HFO-1,1,1,4,4,4-hexafluoro-2-butene (Z-HFO-1336mzz) under the conditions
• thermoplastic polymer comprising polystyrene in the absence of any co-blowing agent.
• the smooth skin indicates the absence of macrovoids and blowholes. Blowholes are macrovoids that have burst through the skin surface.
• the closed cells are uniform in size and have an average cell size of 0.02 to 5 mm, indicating the absence of internal macrovoids.
• the low density is preferably no greater than 48 kg/m 3 .
• thermoplastic polymer comprising polystyrene is preferably high in molecular weight as indicated by their exhibiting a melt flow rate (sometimes called MFR or MFI) of no greater than 25 g/10 min as determined in accordance with the procedure of ASTM D 1238 at 200° C. using a 5 kg weight on the molten polymer.
• MFR melt flow rate
• co-blowing agent can be present in the molten composition in a minor amount relative to the amount of Z-HFO-1336mzz blowing agent present in the molten composition to contribute beneficially to the density and/or closed cell size of the foamed product.
• co-blowing agent is present, the above-described conditions (a)-(d) are followed so that the extrusion process is still one in which above-described foamed product would be obtained, even when the density of the foamed product is no greater than 48 kg/m 3 , using Z-HFO-1336mzz as the sole blowing agent.
• the preferred molecular weight of the thermoplastic polymer comprising polystyrene is the preferred molecular weight of the thermoplastic polymer comprising polystyrene.
• the conditions of operation (a)-(d) when co-blowing agent is present are such that the foam product described above for the present invention would be obtained even if co-blowing agent were not present.
• the presence of co-blowing agent is unnecessary to obtain this foamed product.
• the amount of Z-HFO-1336mzz is increased to replace the amount of co-blowing agent, whereby the total amount of blowing agent obtaining the foamed product is 100 wt % Z-HFO-1336mzz.
• This embodiment of the present invention can be described as a process comprising extruding a molten composition comprising thermoplastic polymer comprising polystyrene and blowing agent comprising Z-HFO-1336mzz (Z-1,1,1,4,4,4-hexafluoro-2-butene) and co-blowing agent, under the conditions
• thermoplastic polymer being foamed according to the present invention comprises polystyrene.
• the polystyrene can be styrene homopolymer or can contain copolymerized monomer other than styrene, i.e. polystyrene copolymer.
• the thermoplastic polymer can also be a blend of polystyrene with other thermoplastic polymer.
• the other thermoplastic polymer can also be a copolymer of styrene with monomer other than styrene.
• a preferred monomer other than styrene is acrylonitrile.
• thermoplastic polymer being foamed is polystyrene or blends of polystyrene with other thermoplastic polymer
• styrene is preferably the dominant polymerized monomer (unit) in the thermoplastic polymer being foamed. More preferably, the polymerized units of styrene constitute at least 70 mol % or at least 80 mol % or at least 90 mol % or at least 100 mol % of the polymerized monomer units making up the thermoplastic polymer being foamed.
• the amount of other monomer copolymerized with the styrene is such that the styrene content of the copolymer is at least 60 mol % of the copolymer, preferably at least 70 mol %, or at least 80 mol % or at least 90 mol % of the copolymer, based on the total mols (100%) making up the copolymer.
• the styrene copolymer is the only styrene-containing polymer in the thermoplastic polymer or is a blend with other thermoplastic polymer, such as styrene homopolymer or other styrene copolymer.
• the thermoplastic polymer being foamed is entirely polystyrene, notably the styrene homopolymer.
• the thermoplastic polymer being foamed is a blend of polystyrene and other thermoplastic polymer as described above, the polystyrene component of this blend is preferably styrene homopolymer constituting at least 80 wt % of the combined weight of polystyrene and other thermoplastic polymer.
• the molecular weight of the thermoplastic polymer comprising polystyrene being foamed is sufficiently high to provide the strength necessary for the requirements of the foam application.
• the strength requirement determines the minimum density of the foamed product.
• the high molecular weight of the thermoplastic polymer comprising polystyrene also contributes to the strength of the foamed product.
• An indicator of molecular weight is the rate at which the molten polymer flows through a defined orifice under a defined load. The lower the flow, the higher the molecular weight. Measurement of the melt flow rate is determined in accordance with ASTM D 1238 at 200° C. and using a 5 kg weight on the molten polymer.
• the weight of molten polymer flowing through the orifice in a defined amount of time enables the melt flow rate to be reported in g/10 min.
• the melt flow rate of the thermoplastic polymer comprising polystyrene is no greater than 20 g/10 min, more preferably no greater than 15 g/10 min, and most preferably, no greater than 10 g/10 min.
• the higher the molecular weight (lower the melt flow rate) the better the foaming result, especially with respect to the attainability of low density foamed products, while still achieving smooth skin on the foamed product.
• the minimum melt flow rate for all the melt flow rates disclose herein is at least 1 g/10 min., whereby the melt flow rate ranges disclosed herein are 1 to 25, 1 to 20, 1 to15, and 1 to10, all values being g/10 min.
• melt flow rate ranges disclosed herein are 1 to 25, 1 to 20, 1 to15, and 1 to10, all values being g/10 min.
• thermoplastic polymer comprising polystyrene also apply to polystyrene by itself.
• disclosure of thermoplastic polymer comprising polystyrene in the preceding paragraph can be replaced by the disclosure polystyrene.
• Another embodiment of the invention is a foam product, comprising: a polymer matrix comprising a thermoplastic material selected from the group consisting of polystyrene, polystyrene copolymers, and blends of polystyrene with other thermoplastic polymers, defining a plurality of cells having an average cell size of from 0.02 to 5 mm, and a blowing agent comprising Z-HFO-1336mzz (Z-1,1,1,4,4,4-hexafluoro-2-butene), having a density of less than 65 kg/m 2 , wherein the thermoplastic polymer has a melt flow rate of less than 25 g/10 min.
• a polymer matrix comprising a thermoplastic material selected from the group consisting of polystyrene, polystyrene copolymers, and blends of polystyrene with other thermoplastic polymers, defining a plurality of cells having an average cell size of from 0.02 to 5 mm
• a blowing agent comprising Z-HFO
• the molten composition being foamed can contain additives other than the polymer being foamed and the Z-HFO-1336mzz blowing agent, such as co-blowing agent, nucleating agent, flame retardant, cell stabilizer agent, surfactant, preservative colorant, antioxidant, reinforcing agent, filler, antistatic agent, IR attenuating agent, extrusion aid, plasticizer, viscosity modifier, and other known additives, all in the amount to obtain the effect desired.
• additives other than the polymer being foamed can contain additives other than the polymer being foamed and the Z-HFO-1336mzz blowing agent, such as co-blowing agent, nucleating agent, flame retardant, cell stabilizer agent, surfactant, preservative colorant, antioxidant, reinforcing agent, filler, antistatic agent, IR attenuating agent, extrusion aid, plasticizer, viscosity modifier, and other known additives, all in the amount to obtain the effect desired.
• the present invention is not limited
• the co-blowing agent is preferably one having negligible ODP and low GWP, e.g. no greater than 150. If a co-blowing agent is used it may be selected from the group consisting of HFC-152a, CO 2 , DME, HFO-1234ze(E), HFO-1234ze(Z), HCFO-1233zd(E), HCFO-1233zd(Z), HCFO-1224yd(E), HCFO-1224yd(Z) and HFO-1234yf.
• the Z-HFO-1336mzz would constitute the major proportion of the total amount of blowing agent.
• the Z-HFO-1336mzz would constitute at least 60 wt % of the total blowing agent, preferably at least 70 wt %, with the co-blowing agent being present in the amounts of 40 wt % and 30 wt %, respectively.
• its minimum amount will be as little as 5 wt % or 10 wt %, whereby the Z-HFO-1336mzz will be present in the 95 wt % and 90 wt % amounts, respectively.
• the preferred blowing agent composition when co-blowing agent is present is 90 to 75 wt % Z-HFO-1336mzz and 10 to 25 wt % of co-blowing agent.
• nucleating agent examples include talc, graphite and magnesium silicate.
• Examples of preferred flame retardants include tetrabromo-bis phenol A and polymeric flame retardants.
• the molten composition is in effect the foamable composition.
• the amount of blowing agent in the molten composition will depend on the amount of additives other than blowing agent and the density desired in the foamed product. Generally, the amount of blowing agent, whether Z-HFO-1336mzz as the sole blowing agent or the Z-HFO-1336mzz blowing agent plus co-blowing agent, will be 5 to 25 wt %, based on the weight of the molten composition.
• the process of the present invention is carried out using an extruder to form the molten composition and to extrude it to form the foamed product.
• the steps (a)-(d) are practiced in and using an extruder.
• the thermoplastic polymer comprising polystyrene forms the feed to the extruder.
• the blowing agent(s) is (are) preferably fed into the extruder at a location intermediate to the feed and extrusion ends of the extruder, typically into the molten composition that is created as the extrusion screw advances the feeds to the extruder along its length.
• the other additives to the molten composition are added where convenient and as may be dictated by the state of the additive.
• solid additives can be conveniently be added to the feed end of the extruder, possibly as a mixture with the polymer feed in particulate form to the extruder.
• the molten composition within the extruder is extruded through a die, thereby allowing the foamable composition to expand into a foamed product.
• the foamed product which can be in such forms as sheet, plank, rod, or tube, is then cooled.
• the present invention resides in certain conditions, unique to extrusion forming of thermoplastic polymers that include polystyrene, under which the extruder is operated.
• the preferred temperature is at least 185° C., more preferably at least 190° C. or at least 200° C. or at least 210° C.
• the preferred maximum temperature for all the melt mixing temperatures disclosed herein is 230° C.
• the melt mixing temperatures disclosed herein are the temperatures of the melt in the mixing zone at the time of mixing.
• the preferred pressure under which the melt mixing is carried out is at least 3000 psi (207 Bar), more preferably at least 3500 psi (241 Bar), more preferably at least 4000 psi (276 Bar).
• the preferred maximum value for all the minimum pressures disclosed under which the melt mixing is carried out is no greater than 5000 psi (345 Bar).
• the pressures disclosed herein are gauge pressures.
• the molten composition is cooled so that the temperature at which the extrusion is carried out is preferably at least 125° C., more preferably at least 130° C.
• the maximum value for all the minimum extrusion temperatures disclosed herein is preferably no greater than 140° C.
• the extrusion temperatures disclosed herein are the temperature of the melt at the time of extrusion.
• the extrusion is preferably carried out with a pressure of at least 1500 psi (103 Bar), more preferably at least 1600 psi (110 Bar).
• the maximum value for the minimum extrusion pressures disclosed herein is preferably no greater than 2000 psi (138 Bar).
• the extrusion pressure is the pressure inside the extrusion die.
• melt mixing pressures of 3000 to 5000 psi (207 to 345 Bar) are preferred for achieving low foam densities of the foamed product, and this temperature range can be used with any of the melt mixing and extrusion temperature ranges to form any of the smooth-skin, closed cell foam product densities disclosed herein.
• melt extrusion pressure range 1500 to 2000 psi (103 to 138 Bar) pressure range together with the 3000 to 5000 psi (207 to 345 bar) pressure range for melt mixing.
• melt mixing 207 to 345 Bar
• extrusion 103 to 138 bar
• melt flow rates for the polymer being foamed of no greater than 25, 20, 15, and 10, and as little as at least 1, all values being in g/10 min, can be used with any of these combinations of pressure and temperatures, depending on the foamed product result desired.
• the conditions (a)-(d) can be used in any combination with any of the polymer melt flow rates and compositions and blowing agent compositions disclosed above.
• thermoplastic polymer comprising polystyrene and polystyrene itself exhibits the following foamed product attributes:
• Closed cells at least 80%, preferably at least 90% and most preferably at least 95%, and having an average cell size of 0.02 to 5 mm,
• Density no greater than 40 g/m 3 and more preferably no greater than 35 kg/m 3 or 30 kg/m 3 , and
• the minimum required strength (compressive) of the foamed product will dictate that the density be at least 16 kg/m 3 .
• the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion.
• a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
• transitional phrase “consisting essentially of” is used to define a composition, method that includes materials, steps, features, components, or elements, in addition to those literally disclosed provided that these additional included materials, steps, features, components, or elements do not materially affect the basic and novel characteristic(s) of the claimed invention, especially the mode of action to achieve the desired result of any of the processes of the present invention.
• the term ‘consisting essentially of’ occupies a middle ground between “comprising” and ‘consisting of’.
• This example demonstrates the use of Z-HFO-1336mzz blowing agent to produce polystyrene foam insulation exhibiting uniform closed cells, smooth skin, and low density. Macrovoids and blowholes are not present in the foam insulation.
• the polystyrene used in this example is styrene homopolymer available as Nova 1600 polystyrene having a melt flow rate of 6 g/10 min.
• This example demonstrates the use of Z-HFO-1336mzz blowing agent to produce polystyrene foam insulation exhibiting uniform closed cells, smooth skin, and low density. Macrovoids and blowholes are not present in the foam insulation.
• the polystyrene used in this example is styrene homopolymer available as Nova 1600 polystyrene having a melt flow rate of 6 g/10 min.
• This example demonstrates the use of Z-HFO-1336mzz/HFC-152a blend containing 77 wt % Z-HFO-1336mzz as the blowing agent to produce polystyrene foam insulation exhibiting uniform closed cells, smooth skin, and low density. Macrovoids and blowholes are not present in the foam insulation.
• the polystyrene used in this example is styrene homopolymer available by Total Petrochemicals as PS 535B having a melt flow rate of 4 g/10 min.
• a nucleating agent (nucleator), namely talc, is present along with the polystyrene and blowing agent in the molten composition formed within the extruder.
• a 50 mm twin screw laboratory extruder was used with 9 individually controlled, electrically heated zones. The first four zones of the extruder were used to heat and soften the polymer. The remaining barrel sections, from the blowing agent injection location to the end of the extruder, were set at selected lower temperatures. An annular die with a 3 mm opening was used in extruding foamed rod specimens.

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• Chemical & Material Sciences (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
• Extrusion Moulding Of Plastics Or The Like (AREA)

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• 2017
  • 2017-05-02 US US16/099,189 patent/US20190218358A1/en not_active Abandoned
  • 2017-05-02 MX MX2018013275A patent/MX2018013275A/es unknown
  • 2017-05-02 EP EP17723828.4A patent/EP3452538A1/en active Pending
  • 2017-05-02 WO PCT/US2017/030587 patent/WO2017192550A1/en unknown
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  • 2017-05-02 CN CN201780027495.9A patent/CN109071862A/zh active Pending
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